Panel



H. l. HAON.

PANEL.

APPLICATION msn yMln/1.1919.

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To all/whom 'it may concern: p

Beit known that'l, HARRY el. l-lAoN, a citizen of the United Sta-tes, residing at Newburgh in the county of @range and State of fork, have invented a certain new and useful Improvement in Panels, of which the followin is a specification.

My inventlon relates particularly pan-V els designed to be applied to doors and which are es ecially applicable for use upon automobile oors.

The object of my invention is to provide door panels which may be advantageously applied in the manufacture of automobile doors. My -object`is to avoid any disadvantages which would be present if .or when such panels were manufactured as follows:

A sheet of cardboard .was cut out the shape of the door to which the panel was to be applied, a hole beine left for the tool pocket in the center of the door, and a hole being made ltherein to receive' the latch mounted uponthe door for fastenin the latter; Upon thisthere was pasted by and an embossed piece of .leather or artificial leather an inch larger around v .the edges than the cardboard blank. This layer of tit ttl

leather or artificial leather was then pasted to the cardboard blank by hand, vpressure being applied by means of a roller or scraper to remove blisters.. Thereafter, the edges of the leather or artificial leather were turned over the edges of the cardboard and pasted down thereon. This resulted obviously in the partial removal of the embossing, and brought about a lack of uniformity which -is undesirable. After'this, the panel was sezured to the ifnner face of the lior ap ing a strip o gim around the e tliereopfyand driving tacks Ithrough the inigp and panel into the .wooden frame o the door. The door flap to cover the tool pocket inthe door was constructed in the same manner and applied to the up eredge'of the pocket opening in substantie ly the same way a layer of paint 'or enamelbeing'ap# plied to the inner face of said flap' to give it an attractive finish. This method required .the use of expensive finishing materials, such as leather or thick artificial leather; and also required a large amount of hand worlcThs resulted in making the product very expensive. lt is the object of my inventon to provide panels suitable for appli- Specification of Letters Patent. attentedl limit. lll, l92ll i Application tiled May l, A11919. Serial No. 294,023.

avoids the disadvantages of the above panels.

While my invention is capable of being carrled out in many dierent ways, forl the purpose of illustration l shall describe only one way in which panels made in accordance with my invention may be constructed, and have shown only one form of apparatus for use in the manufacture of the same in the accompanying drawings, in which:

Figure 1 is a diagrammatic representat1on o f an apparatus which may be used for carrylng out my invention.

Fig. 2 is an elevation of an inner face of an automobile touring body, and

Fig. 3 is a end elevation partly in section showing an automobile door equipped rcated on the inner side thereof. From Athis 'point the artificial leather 1 passes by a doctor blade 4l in advance of which an adhesive material, as for example a composition made as follows: A water paste composed of flour, starch or glue, or a pyroxylin 0r a rubber solution, is applied to the artificial leather. Beyond this point there are applied in succession to the artificial leather, plates or sheets of cardboard 5 which may be of a material heavier and stider than is ordinarily marketed in roll form and which need not have the shape of any particular automobile door to whlch the finished panels are to be4 applied. From this point the artificial leather carrying the plates of cardboard 5 preferably passes into a drying chamber 6 heated by means such as a steam coil 7, said drying chamber 6 being for the 'purpose merely of partially drying the adhesive-composition. The artificial leather 1 carrying the cardboard plates 5 preferaby passes thence between a pair of calen er rolls 8 and 9 driven by' any suitable source of power, and subjected to any desired pressure, so as to completely anchor the cardboard plates on the artificial leather.

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From this point the web of material passes through a cutting apparatus of any desired type indicated at 10 and 11, so as to sever the artificial leather into portions, which may be referred to as blanks and which are ordinarily of substantially the same size and shape as the plates of cardboard 5. Thereupon the blanks or sheets of combined cardboard and artificial leather are ordinarily allowed to stand for a number of hours until they are completely dried. Then any desired embossing may be applied to the same by introducing these sheets into an embossing` press of any desired character which will simultaneously heat and emboss said sheets. In this Way, as soon as the sheets have cooled they Will have acquired a permanent embossing which is not ordinarily in any Way modified or obliterated in 'the process of manufacture. In the present exemplifieation of my method, these sheets are now cut out into the general external shapes desired in order to conform the same to the shapes of the doors to which they are to be applied, and so as to form panels 12 for this purpose, any desired holes 14 and 15 being optionally punched in said panels for the tool pocket and a latch fastening 16 at the same time. These panels 12 are ordinarily thereupon provided With a binding around the edges thereof and this binding may consist of a strip of artificial leather 17 of the same character as was applied to the cardboard plates, said strip 17 being preferably secured to the panel by means such as sewing. Thereupon, I may form a door flap 18, which is ordinarily produced inthe same manner as one of the panels 12, except that on the inner face of said door panel I may apply in a similar manner a layer of a dyed covering fabric 19, as for example sheeting or drill, or instead I may use, to finish this surface, merely a coating of an asphalt paint. This door flap '18 may be secured to the panel 12 bysewing or in any other desired manner. A completed panel may be applied to v the inner face ofan automobile door, by inserting unholsteryl tacks 20, so as to cause the same to be received in a Wooden frame 21 of the door which may have on the outside face thereof, a metal facing 22. The edge of the door frame 21 may, if desired, be covered with a strip of material 23 similar to the artificial leather 1 in order to provide the desired finish.

By making the door panels in this manner, an entirely permanent embossing is obtained, a thinner and less expensive finishing material can be used, and there is a `saving of labor at many different points, as for example in the mechanical pasting, the single cutting operation for both layers of material to fit the door, and in the finishing of the ed e ofthe panel in one operation.

he process of making a door panel claimed in this case has been claimed in applicants copending case Serial No. 294,024, filed May 1, 1919.

While I have described my invention above in detail, I Wish it to be understood that many changes may be made therein without departing from the spirit thereof.

Claims:

1. A door panel blank prepared by applying an adhesive material and then a separate plate of cardboard to an advancing web of artificial leather, partially drying, then calendering and then cutting to the approximate size of said plate.

2. A door panel blank as described in claim 1, but which has been dried after cutting as described, and thereafter embossed.

3. A door panel as described in claim 1, but which has been dried after cutting as described, and thereafter embossed and ,cut to a final shape.

4. A door panel as described in claim.1, but which has been dried after cutting, as described, thereafter embossed and cut to a final shape comprising apertures, the cutting to shape and the cutting of apertures being effected in one operation.

5. A door panel as described in claim 1, but which has been dried after cutting, as described, then embossed, and then cut te provide in one operation for both general external shape and for any desired holes, and thereafter bound.

6. A door panel comprised of a layer of cardboard having applied to the face thereof a layer of thin fiexible material, and a door flap secured to the panel and constructed in. substantially the same manner, but having its inner face provided with a finish.

7. A door panel comprised of a layer of cardboard having applied to the face thereof a layer of thin artificial leather, and a door flap secured to the panel and constructed in substantially the same manner, but having its inner face provided with a finish.

8. A door panel comprised of a layer of cardboard having applied to the face thereof a layer of thin flexible material, the edge thereof being bound with a strip of thin fiexible material, and a door flap secured to the panel and constructed in substantially the same manner, but having its inner face provided with a finish.

9. A door panel comprised of a layer of cardboard having applied to the facev thereof a layer of thin artificial leather, the edge thereof being bound with a strip of thin artificial leather, and a door flap secured to the panel and constructed in substantially the same manner, but having its inner face provided With a finish.

In testimony that I claim the foregoing, I have hereunto set my hand this 23d day of April, 1919.

HARRY J. HAON. 

